Insulated prime door

ABSTRACT

A metal faced door with a foam filled core. An extruded plastic casing member extends around the entire periphery of the door to join the metal facing panels. Direct contact between the inner and outer panels is avoided. The plastic extrusion also carries screw retaining plates usually around the entire periphery of the door.

United States Patent [191 Vance 1 Aug. 7, 1973 INSULATED PRIME DOOR [75] Inventor: William R. Vance, Agincourt,

Ontario, Canada 221 Filed: Feb. 28, 1972 21 Appl. No.: 229,975

[52] U.S. Cl 49/501, 49/488, 52/620 3,314,196 4/1967 Betz et a] 49/501 2,927,354 3/1960 Lauer 49/501 X 3,683,555 8/1972 Kuniansky 49/503 2,204,818 6/1940 Obermayr 52/619 X 3,512,305 5/1970 Multer .49/503 Primary Examiner-Mervin Stein Assistant Examiner-Philip C. Kannan Attorney-Vern L. Oldham et a1.

' s7 ABSTRACT I l t. l E 1 g Search 49/501 i ga f A metal faced door with a foam filled core. An ex- 49/1316 2 619 6 truded plastic casing member extends around the entire periphery of the door to join the metal facing panels, Direct contact between the inner and outer panels is [56] References Cited avoided. The plastic extrusion also carries screw retaining plates usually around the entire periphery of the UNITED STATES PATENTS door 3,373,538 3/1968 Prager 52/619 X 3,599,703 8/1971 Mennuto et a1. 49/501 X 9 Claims, 6 Drawing Figures 5| 55 no 30 s\30(1 I \68 J r 24 v f v 1/;

INSULATED PRIME DOOR The present invention relates to a metal faced door construction and more particularly, to such a construction having improved appearance and insulating properties.

In a door having metal inner and outer facings it is preferable that the inner and outer facings be separated at allpoints by insulating material. If the inner and outer metal skins of the door are permitted to contact one another along the edges of the door, thermal conduction between the two skins will occur. This is undesirable, particularly where the door is used as an exterior door of a structure since the inner facing of the door will lose heat to the outer facing.

One prior solution to this problem has been to use wooden edge members for the door with the metal skins being secured in some prior doors in grooves of the edge members. However, these wooden members are subject to warpage and the presence of grooves on the door edges detracts from the finished appearance of the door. In some prior door constructions, additional difficulties are encountered as the hinge leaves span the space between the inner and outer metal skins andthus form thermal bridges defeating the purpose of the insulating separating material between the two skins.

It is the primary object of the present invention to provide a metal faced door construction which has improved insulating properties, the metal skins being fully separated froM one another so that thermal conduction between the two skins does not occur.

It is a further object of the present invention to provide a metal door construction which includes means to secure the hinges to the door without producing thermal bridges between the inner and outer metal facings of the door.

It is also an object of the invention to provide a metal faced door construction which is of improved appearance.

The above and other objects of, the invention which will become apparent in the following detailed description are achieved by providing a door construction which consists, essentially, of an inner metal skin, an outer metal skin, and a rigid extruded plastic connector or casing member extending around the periphery of the door and joining the two skins while maintaining a thermal separation therebetween. The extrusion also carries screw receiving plates so that the hinges and other hardware may be secured thereto without producing a thermal bridge between the inner and outer skins.

For a more complete understanding of the invention and the objects and advantages thereof reference should be had to the following detailed description and the accompanying drawings wherein there is shown a preferred embodiment of the invention.

In the drawing:

FIG. 1 is an elevational view of the door of the present invention;

FIGS. 2 and 3 are vertical sectional views taken along the lines 2-2 and 3-3, respectively, of FIG. 1;

FIGS. 4 and 5 are horizontal sectional views taken along the lines 4-4 and 55, respectively, of FIG. I; and

FIG. 6 is an enlarged cross-sectional view of the rigid plastic extrusion employed in the door assembly of the present invention.

The door, designated generally by the reference numeral 116, is designed for use in a conventional door frame having side members 12 and I4, a header l6, and a sill plate I8. The door is carried by hinges 20 and includes a latch mechanism 22..

As will be seen from FIGS. 2-5, the door 10 has an inner metal skin or facing panel 24 and an outer skin or facing panel 26. These panels are preferably formed of sheet steel and may have a protective and decorative finish. The void between the inner and outer skins 24 and 26 is filled with foam 28 which may, for example, be a foamed-in-place urethane foam.

The edges of each of the skins 24 and 26 are bent to have a substantially Z-shaped configuration in crosssection. Thus, each edge has a first portion 30 which extends inwardly at an angle to the skin and a second portion 32 at the inner end of the intermediate portion 30, the second portion extending generally parallel to the skin. These bent edge portions 30, 32, and 30a, 32a of. the metal skins 24 and 26, respectively, have snapping engagement with opposite sides of a casing member 36 which, preferably, is an extruded rigid plastic member.

The casing member 36 is illustrated in FIG. 6. This member may be formed of rigid polyvinychloride, for example. It should be understood that the term rigid when used in describing the casing member 36 is intended to connote that the material forming the casing is relatively inflexible. However, a slight degree of flexibility is present. The casing 36 has a substantially flat center web 36 from which two legs 40 extend in diverging relation to define a V-shaped groove 50 extending the length of the casing. It will be noted that the casing is symmetric about an axis through the apex of the V- shaped groove 50. Each of the legs 40 terminate in a base web 42 which extends parallel to the central web 38. The outer end of each of the base webs 42 has a ridge on the side of the web toward the central web 38 to provide a groove 43 adjacent the leg 40. The surface of the central web 33 adjacent the base webs 42 is also provided with ribs 44. As will be seen from FIGS. 2-5, the groove or recess 43 and ribs engage the bent edge portion 32 or 32a of the door skin in a tight fitting relationship with the V-shaped groove of the casing member 36 being directed towards the edge of the door. The groove 43 and ribs or shoulders 44 may be considered to form channels in which the inner legs of the door edges are received. It will be noted that the two skins 24 and 26 are thus held in fixed relation relative to one another but are not in direct contact at any point, the casing member 36 providing an insulating barrier between the inner and outer skins.

Referring again to FIG. 6, it will be seen that the base webs or flanges 62 of the casing member 38 have portions 46 which are directed towards one another and on the facing sides of the legs 46. These inwardly projecting portions 66 provide grooves 48 extending the length of the casing member 38. In order to provide an attractive appearance for the finished door assembly, a plastic trim strip 56 which has inwardly projecting ridges 53, is snapped or forced into engagement with the grooves 63 of the casing member 38 by flexure of the legs 4M). The lateral edges 55 of the trim strip 50 engage the angled portions 36 and 36a of the skins 24 and 26, respectively. This trim strip 51 may also be formed of a rigid plastic, for example, a rigid polyvinylchloride. The trim strip 51 extends along the entire side and top edges of the door with the exception of the regions of the hinges 20 and the latch mechanism 22. A flexible weather strip 58 may be carried in the casing 12 and the header 16 to engage the outer surface of the trim strip 51 to provide a tight seal between the door and the casing, in the conventional manner.

Along the bottom edge of the door a channel member 60, which may be either a metal or plastic extrusion, is affixed to the lower surfaces of the base flanges 42 and the door by means of screws 61 extending through the channel 60 into the door. A suitable flexible sealing strip or gasket 64 is carried in the channel for engagement with a metal sill plate 66. This arrangement may, of course, be omitted when the door is designed for interior use.

The surface of the central web 38 of the casing member 36 which is directed towards the interior of the door, that is the surface opposite that from which the legs 40 project, is provided with L-shaped upwardly projecting ridges or flanges 52 to define a generally rectangular channel or retainer opening 54 extending the length of the casing member 36. The casing members 36 mount or retain metal plates 68, usually steel, in the channels 54. Individual plates 68 preferably are provided to extend the lengths of all margins of the door. The sealing strip 62 is secured to a plate 68 by the screws 61. Other hardware means for the door may also be secured to others of the plates 68, as all screws engage tapped holes in the plates.

As will be seen from FIG. 5, the leaf 70 of the hinge 20 is secured to the door by means of screws which pass through the leaf and which are threaded into the steel plate 68, the leaf 70 resting against the outer edge of the base webs 42. The opposite leaf 74 of the hinge 20 is secured to the casing member 14, for example, with conventional wood screws. It should be noted that the leaf 70 contacts the plastic casing member 36 but does not make direct contact with the skin 24, the base web 42 insulating the leaf 70 from the angled portion 30 of the metal skin 24 while the central web 38 insulates the screw anchoring plate from the skin 24. As a result, there is no thermal bridge formed by the hinge between the inner and outer skins 24 and 26.

Although the door has been illustrated and described as a single, side hinged door, the construction of the present invention may be used with other door arrangements. The essential feature of the invention is the use of the rigid" plastic casing member 36 to join the metal facing panels 24 and 26 while maintaining a thermal barrier between the facing metal panels.

It will be seen that the casing members 36 are snapped or forced into engagement with the edge portions 32, 32a of the door panels that then are locked in their assembled positions, as are the trim strips 51.

By having the plates 68 along all margins of the door, they are adapted to be used as either lefts or rights" by rotating the doors 180 so that the hinge and door lock edges are provided on the desired vertical edge of the door and suitable hardware can be secured thereto.

While only the best known embodiments of the invention have been illustrated and described in detail herein it will be understood that the invention is not limited thereto or thereby. Reference should therefore be had to the appended claims in determining the true scope of the invention.

What is claimed is:

l. A door, comprising:

an outer metal facing panel the edge portions of which are of a Z-shaped configuration having a first portion extending at an acute angle to the plane of the panel and a second portion extending from the edge of the first portion and substantially parallel to the plane of the panel;

an inner metal facing panel the edge portions of which are of a Z-shaped configuration having a first portion extending at an acute angle to the plane of the panel and a second portion extending from the edge of the first portion and substantially parallel to the plane of the panel; and

easing members extending along the edges of the door, the casing members having continuous channels on opposite sides thereof engaging the second portions of the outer and inner facing panels.

2. The door according to claim 1 wherein the casing members are plastic extrusions and are sprung into engagement with said door panel edge portions.

3. The door according to claim 1 wherein a metal plate is carried on a central web provided on each of the casing members for engaging hardware attaching means to secure same to the door.

4. The door according to claim 3 wherein the inner surface of the central web of the casing member is provided with a pair of flanges or ridges of L-shape in cross section to provide a channel for receiving the metal plate.

5. The door according to claim 1 wherein the space between the inner and outer facing panels is filled with foamed in place urethane foam material.

6. The door according to claim 1 wherein each casing member has a substantially flat central web extending parallel to the door edge and a pair of diverging webs extending from a center portion of the central web, each diverging web and the corresponding edge portion of the central web forming one of the continuous channels.

7. The door according to claim 6 further including a trim strip extending along the exposed edges of the door, the trim strip having a main portion spanning the distance between the outer and inner face panels and a projecting portion extending generally perpendicular to the main portion and engaging the casing member between the diverging webs thereof.

8. The door according to claim 6 wherein the door is attached to a door frame by hinges, the hinges being secured to the door by means of screws passing through one leaf of the hinge and through the casing member.

9. A door, comprising:

an outer planar metal facing panel the edge portions of which are of substantially Z-shaped configuration having a first portion extending inwardly at an acute angle to the plane of the panel and a second portion extending laterally outwardly from the edge of the first portion and substantially parallel to the plane of the panel;

an inner planar metal facing panel the edge portions of which are of substantially Z-shaped configuration having a first portion extending inwardly at an acute angle to the plane of the panel and a second portion extending laterally outwardly from the edge of the first portion and substantially parallel to the plane of the panel; and

casing members extending along the edges of the door, the casing members having continuous means on opposite sides thereof engaging portions of the Z-shaped configurations of the outer and inner facing panels to be secured in place thereby.

t t i Q t 

1. A door, comprising: an outer metal facing panel the edge portions of which are of a Z-shaped configuration having a first portion extending at an acute angle to the plane of the panel and a second portion extending from the edge of the first portion and substantially parallel to the plane of the panel; an inner metal facing panel the edge portions of which are of a Z-shaped configuration having a first portion extending at an acute angle to the plane of the panel and a second portion extending from the edge of the first portion and substantially parallel to the plane of the panel; and casing members extending along the edges of the door, the casing members having continuous channels on opposite sides thereof engaging the seconD portions of the outer and inner facing panels.
 2. The door according to claim 1 wherein the casing members are plastic extrusions and are sprung into engagement with said door panel edge portions.
 3. The door according to claim 1 wherein a metal plate is carried on a central web provided on each of the casing members for engaging hardware attaching means to secure same to the door.
 4. The door according to claim 3 wherein the inner surface of the central web of the casing member is provided with a pair of flanges or ridges of L-shape in cross section to provide a channel for receiving the metal plate.
 5. The door according to claim 1 wherein the space between the inner and outer facing panels is filled with foamed in place urethane foam material.
 6. The door according to claim 1 wherein each casing member has a substantially flat central web extending parallel to the door edge and a pair of diverging webs extending from a center portion of the central web, each diverging web and the corresponding edge portion of the central web forming one of the continuous channels.
 7. The door according to claim 6 further including a trim strip extending along the exposed edges of the door, the trim strip having a main portion spanning the distance between the outer and inner face panels and a projecting portion extending generally perpendicular to the main portion and engaging the casing member between the diverging webs thereof.
 8. The door according to claim 6 wherein the door is attached to a door frame by hinges, the hinges being secured to the door by means of screws passing through one leaf of the hinge and through the casing member.
 9. A door, comprising: an outer planar metal facing panel the edge portions of which are of substantially Z-shaped configuration having a first portion extending inwardly at an acute angle to the plane of the panel and a second portion extending laterally outwardly from the edge of the first portion and substantially parallel to the plane of the panel; an inner planar metal facing panel the edge portions of which are of substantially Z-shaped configuration having a first portion extending inwardly at an acute angle to the plane of the panel and a second portion extending laterally outwardly from the edge of the first portion and substantially parallel to the plane of the panel; and casing members extending along the edges of the door, the casing members having continuous means on opposite sides thereof engaging portions of the Z-shaped configurations of the outer and inner facing panels to be secured in place thereby. 